Process of making a wrapped tampon

ABSTRACT

This invention relates to a process for making a wrapped tampon. A continuously moving wrapper material is provided with a longitudinal axis, width and a tear member. The wrapper material is maintained in a pre-determined rotational position. The wrapper material provided also has a pair of opposing longitudinal edges that are folded and sealed together to form a longitudinal seal. The wrapper material is cut to form a pair of opposing transverse edges. The transverse edges are to form a transverse seal having a width defined by a first end and a second end. A tampon is provided and is inserted into the wrapper material through the unsealed opposing transverse edges that are subsequently sealed. At the end of the process, when the wrapper is sealed the tear member extends into the transverse seal adjacent to the first end.

FIELD OF THE INVENTION

[0001] This invention relates to catamenial tampons, and moreparticularly, process for making a wrapped tampon.

BACKGROUND OF THE INVENTION

[0002] Current tampon wrappers may or may not comprise tear members tohelp facilitate opening of the wrapper. As well, the tear members ofcurrent tampon wrappers are not consistently placed on the wrapperswithin a given package. Because of this inconsistency, many consumersmay not be aware that there are tear members available to facilitateopening of tampons. The process of the present invention provideswrapped tampons with consistently placed tear members. The process ofthe present invention may optionally include a step of providing anidentification graphics overlying the tear member. The resultingconsistently placed tear member and the optional identification graphicact as an indicator of the location of the tear member and willfacilitate the consumer in properly exposing the tampon for use.

SUMMARY OF THE INVENTION

[0003] This invention relates to catamenial tampons, and moreparticularly, a process for making a wrapped tampon. A continuouslymoving wrapper material is provided that has a pair opposinglongitudinal edges, a longitudinal axis and a width. The material ispositioned in a pre-rotational positional position. A tear member isprovided and is attached parallel to the longitudinal axis. The wrappermaterial is folded along the longitudinal axis to overlap the pair ofopposing longitudinal edges, which are then sealed together to form alongitudinal seal. The wrapper material is cut to form a length and apair of opposing transverse edges. The wrapper material is maintained ina pre-determined rotational position. The wrapper material is sealed inone of the transverse edges to form a transverse seal having a widthdefined by a first end and a second end. A tampon is provided and isinserted into the wrapper material through the unsealed transverse edge,which is then sealed to form a transverse seal having a width defined bya first end and a second end. When the wrapper is sealed the tear memberextends into the transverse seal adjacent to the first end.

BRIEF DESCRIPTION OF THE DRAWINGS

[0004] While the specification concludes with claims particularlypointing out and distinctly claiming the subject matter that is regardedas forming the present invention, it is believed that the invention willbe better understood from the following description taken in conjunctionwith the accompanying Figures, in which:

[0005]FIG. 1 is a block diagram of the process of the present invention.

[0006]FIG. 2A is an isometric view showing the orientation of therotating cam, the rotating shear knife and the slotted drum used in theprocess of the present invention.

[0007]FIG. 2B is a front view showing the orientation of the rotatingcam, the rotating shear knife and the slotted drum used in the processof the present invention.

[0008]FIG. 3 is a right isometric view of the rotating cam.

[0009]FIG. 4 is a plan view of wrapped tampon of the present inventionincorporating a wrapper having a pair of opposing transverse seals, alongitudinal axis and a tear member.

DETAILED DESCRIPTION OF THE INVENTION

[0010] All documents cited are, in relevant part, incorporated herein byreference; the citation of any document is not to be construed as anadmission that it is prior art with respect to the present invention.

[0011] As used herein “compressed” refers to pressing or squeezingtogether or to reduce in size or volume as if by squeezing. The tamponsherein are typically formed by laterally compacting or rolling thepledget such a process results in a compressed structure that issuitable from insertion into the vaginal cavity.

[0012] The term “joined” or “attached” as used herein, encompassesconfigurations in which a first element is directly secured to secondelement by affixing the first element directly to the second element;configurations in which the first element is indirectly secured to thesecond element by affixing the first element to intermediate member(s)which in turn are affixed to the second element; and configurations inwhich first element is integral with second element; i.e., first elementis essentially part of the second element.

[0013] As used herein the terms “pledget” or “tampon pledget” isintended to be interchangeable and refer to a construction of absorbentmaterial prior to the compression of such construction into a tampon asdescribed above.

[0014] As used herein the term “pre-determined rotational position”refers to the orientation of the tear member to the transverse seal suchthat the tear member is located on or about 3 mm, or typically 2 mm awayfrom the first end of the transverse seal.

[0015] The term “rotating cam” refers to one mechanism that is used tomaintain the wrapper material is a pre-determined rotational position.The rotating cam has a major diameter, minor diameter and twotransitional areas between the major and minor diameter. The majordiameter is the portion of the rotating cam that contacts the wrappermaterial, stabilizes the wrapper material in the pre-determinedrotational position, and remains in contact with the wrapper materialuntil it is securely placed into the slotted drum ports. The majordiameter is sized such that its face velocity when rotating is equal tothe linear speed of the upcoming tube. The major diameter has a radialrelief that is sized and shaped approximately equal to the diameter ofthe wrapper material. The axis of the radial relief is perpendicular tothe rotational axis of the rotating cam.

[0016] As used herein the term “tampon” refers to any type of absorbentstructure that is inserted into the vaginal canal or other body cavitiesfor the absorption of fluid there from, or for the delivery of activematerials, such as medicaments, or moisture. Tampons are generally“self-sustaining” in that they will tend to retain their general shapeand size before use. The tampon has a withdrawal end opposed to aninsertion end. A typical compressed tampon is 40-60 mm long measuredfrom the withdrawal end to the insertion end along the longitudinalaxis. A typical compressed tampon is 10-16 mm wide corresponding to thelargest cylindrical cross section although the width may vary along thelength.

[0017] As used herein the terms “vaginal cavity,” “within the vagina”and “vaginal interior,” are intended to be synonymous and refer to theinternal genitalia of the human female in the pudendal region of thebody. The term “vaginal cavity” as used herein is intended to refer tothe space located between the introitus of the vagina (sometimesreferred to as the sphincter of the vagina) and the cervix and is notintended to include the interlabial space, including the floor ofvestibule. The externally visible genitalia is generally not includedwithin the term “vaginal cavity”.

[0018] As used herein, “cm” is centimeter, “dpf” denier per foot, “g” isgrams, “gms” is grams per square meter “mm” is millimeters, “ml” ismilliliters, “rpm” rate per minute, and “sec” is seconds.

[0019] While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention.

[0020]FIG. 1 is a block diagram of the process of the present invention.A continuously moving wrapper material is provided having a longitudinalaxis, a pair of opposing longitudinal edges, and a width. A tear memberis provided and may be attached after the wrapper is provided or thetear member may be already attached. Regardless of when it is attached,the tear member is attached parallel to the longitudinal axis. Thematerial is positioned in a pre-determined rotational positioned. Thewrapper material is then folded along the longitudinal axis to overlapthe pair of opposing longitudinal edges, which are then sealed togetherto form a longitudinal seal. The wrapper material is cut to form alength and a pair of opposing transverse edges. The wrapper material istypically cut to a length that is longer than the axial length of thetampon. The wrapper material is maintained in a pre-determinedrotational position. The wrapper material is sealed on one of thetransverse edges of the wrapper material to form a transverse sealhaving a width defined by a first end and a second end. A tampon isprovided and is inserted into the wrapper material through the unsealedopposing transverse edge, which is then sealed to form a transverseseal. When the wrapper is sealed the tear member extends into thetransverse seal adjacent to the first end.

[0021]FIG. 2A is an isometric view showing the orientation of therotating cam, the rotating shear knife and the slotted drum in a machinethat may be used in the process of the present invention. The wrappermaterial 22 is feed by a conveyor and in some embodiments of the processof the present invention, the rotating cam 6 is used to maintain thewrapper material in a pre-determined rotational position. The rotatingshear knife 8 is used to cut the wrapper material to a length. Therotating cam 6 is located downstream of the rotating shear knife 8. Therotating cam 6 and rotating shear knife 8 rotate at coordinated speeds(rpm). The rotating cam comes into contact with a tube of wrappermaterial 22 prior to the cutting with the rotational shear knife 8 andbegins pushing the tube of wrapper material on angle into a ports 12,(as shown in FIG. 2B) on a slotted drum 10.

[0022]FIG. 2B shows the front view shows the ports on the slotted drum10. In some embodiments, the tube of wrapper material begins to engagethe slotted drum ports 12, a vacuum port (not shown) in the rotating camopens and the vacuum maintains the tube of wrapper 22 material in itspre-determined rotational position in the slotted drum ports 12.

[0023]FIG. 3 shows a right isometric view of the rotating cam 6 that maybe used to maintain the wrapper material in a pre-rotational position.The rotating cam 6 has a major diameter 14 and a minor diameter 16, andtwo transitional areas 18 between the major and minor diameter. Themajor diameter 14 of the rotating cam 6 has a radial relief 20 that issized and shaped approximately equal to the diameter of the wrappermaterial is cut in the major diameter 14 segment. The major diameter 14segment of the cam is the portion that comes into contact with thewrapper material and stabilizes it.

[0024]FIG. 4 shows a plan view of one embodiment of such a wrappedtampon resulting from the process of the present invention. The wrappermaterial 22 has a length 24 longer than the axial length of the tampon,a pair of opposing transverse seals 28, a longitudinal axis “L” and atear member 38. The transverse seals 28 of the wrapper have a width 32defined by a first end 34 and second end 36. The longitudinal seal 30 isoriented parallel to the longitudinal axis “L”. The tear member 38 isoriented parallel to the longitudinal axis “L” and extends into each ofthe transverse seals 28 adjacent to the first ends 34 of each of saidtransverse seals 28. One of said transverse seals 28 is atear-initiating end.

[0025] I. Tampon of the Present Invention:

[0026] The tampon of the present invention is comprised of a compressedabsorbent material. The tampon has an axial length, a circumference, andan insertion end opposed to a withdrawal end. The tampon may be anysuitable size and thickness suitable for insertion in the vaginal cavityof the user. In some embodiments, the absorbent material is generallysquare or rectangular, but other shapes such as trapezoidal, triangular,hemispherical, chevron and hourglass shaped are also acceptable. Atypical size for absorbent material prior to compression may be fromabout 40 mm to about 100 mm in length and from about 40 mm to about 80mm in width. In general, the absorbent material is 40 mm to 60 mm inlength and from about 50 mm to about 70 mm in width. The typical rangefor the overall basis weight is from about 150 gms to about 800 gms.

[0027] The tampon of the present invention may be constructed from awide variety of liquid-absorbing materials commonly known in the art andused in absorbent articles such as rayon (including tri-lobal such asGALAXY Rayon (a tri-lobed rayon structure) available as 6140 Rayon fromAcordis Fibers Ltd., of Hollywall, England and conventional rayonfibers, and needle punched rayon), cotton (long fibers, short fibers,cotton linters, T-fibers, card strips, comber cotton), or comminutedwood pulp. The materials for the tampon can be formed into a fabric,web, or batt that is suitable for use in the absorbent material by anysuitable process such as airlaying, carding, wetlaying, hydroentangling,needling or other known techniques.

[0028] If the compressed absorbent member of the present invention islayered, the layers may comprise different materials. For example, inone embodiment, the outer layers may comprise primarily rayon, while theintermediate layer or layers may comprise primarily cotton. Optionally,the entire compressed absorbent member may comprise a uniform ornon-uniform blend of materials throughout. In one-layered embodimentseach of the layers may comprise essentially 100% of the same material,such as outer layers of 100% rayon and an intermediate layer of 100%cotton. A Super Plus absorbency tampon of the present invention may bemade from a pledget comprising about 100% rayon fibers. A Superabsorbency or regular absorbency tampon of the present invention may bemade from a pledget comprising about 25% cotton and about 75% rayonfibers. A junior absorbency tampon may be made from a pledget comprisingabout 67% cotton and about 33% rayon fibers.

[0029] Pressures and temperatures suitable for compression are wellknown in the art. Typically, the absorbent material and the fluidwicking overwrap is compacted in the radial direction and optionally inthe axially along the longitudinal and lateral axes by any means wellknown in the art. While a variety of techniques are known and acceptablefor these purposes, a modified tampon compressor machine available fromHauni Machines, Richmond, Va., is suitable.

[0030] In one embodiment, the tampon of the present invention maycomprise a withdrawal means. The withdrawal means will be joined to thetampon and will be graspable for removal after use. The withdrawal meansmay be joined to any suitable location on the tampon and extends beyondat least the withdrawals end. Any of the withdrawal means currentlyknown in the art may be used as a suitable withdrawal mechanism. Inaddition, the withdrawal means can take on other forms such as a ribbon,loop, tab, or the like. The withdrawal means may be attached in anysuitable manner known in the art including sewing, adhesive attachment,or a combination of known bonding methods.

[0031] The tampon of the present invention may be inserted digitally orthrough the use of an applicator. Any of the currently available tamponapplicators may also be used for insertion of the tampon of the presentinvention. Such applicators of typically a “tube and plunger” typearrangement and may be plastic, paper, or other suitable material.Additionally, a “compact” type applicator is also suitable.

[0032] II. The Wrapper of the Present Invention:

[0033] The wrapper has a length longer than said axial length of thetampon and a width as greater than the circumference of the tampon. Thewrapper of the present invention is typically 130-180 mm in length and40-80 mm in width. The wrapper has a pair of opposing transverse seals,a longitudinal axis “L” and a tear member. The transverse seals of thewrapper have a width defined by a first end and second end. Thetransverse seals of the wrapper are 20-40 mm in width. The transverseseal are 1-5 mm in height. The longitudinal seal is orientedsubstantially parallel to the longitudinal axis “L” and extends intoeach of said transverse seals. The longitudinal seal may be positionedequidistant from the first end and second end of the transverse seal.

[0034] The tear member is oriented substantially parallel to thelongitudinal axis “L” and extends into each of the transverse sealsadjacent to the first ends of each of said transverse seals. The tearmember may be oriented parallel to the longitudinal seal. The tearmember may be located about 3 mm from the first ends of the transverseseals. Typically, the tear member may be located within about 2 mm ofthe first ends of the transverse seals. One of said transverse seals maybe a tear-initiating end. The tampon may be oriented such that thewithdrawal end or the insertion end of the tampon is oriented within thewrapper adjacent to the tear-initiating end.

[0035] The walls of the wrapper can be of any desired thickness,commensurate with the intended use. Generally, the walls are flexibleand fluid-impermeable. Typically, the walls of package 2 have athickness of from about 0.0127 mm (0.5 mil) to about 0.127 mm (5.0mils). The wrapper can be made of laminates of plastic and paper, orpaper fibers with fillers (RFS ECUSTA INC. Pisgah Forest, N.C. 28768).Typically the tear member is attached to the wrapper material when it isreceived. The tear member may be a bead of glue or a thread.

[0036] The wrapper material may optionally have an identificationgraphic on the opposite side overlaying the tear member. The optionalidentification graphic may depict the location of the tear member. Theoptional identification graphic may depict or recite instructions to aidthe consumer in using the tear member to properly expose the tampon foruse.

[0037] III. The Process of Making the Wrapped Tampon:

[0038] While several methods of making the tampon of the presentinvention would be apparent to one of skill in the art in light of thedisclosure herein, the previous description in DETAILED DESCRIPTION OFTHE INVENTION in conjunction with the accompanying FIG. 1 is one methodof making a wrapped tampon of the present invention.

[0039] IV. Example of the Process:

[0040] In one embodiment of the process, a roll of wrapper materialhaving a longitudinal axis and a width is provided and is unwound. Thewrapper material provided has a tear member joined or secured theretoand a pair of opposing longitudinal edges. The wrapper material ispositioned in a pre-determined rotational position and placed on aconveyor. The wrapper material is formed over a mandrel along thelongitudinal axis to overlap the pair of opposing longitudinal edge andform a continuous tube of wrapper material. The wrapper material withthe pair of opposing longitudinal edges is sealed together to form alongitudinal seal by a rotating pair of knurled nip rollers.

[0041] Next, the wrapper material is continuously fed through therotating shear knife that cuts the wrapper material into discretelengths or wrapper tubes. The wrapper tubes are open at both ends and afed into a slotted drum with ports formed around its circumference. Thecontrol of rotation and the orientation of the tear member on thewrapper tubes can be accomplished by various methods. For example, theslotted drum and the wrapper material may be aligned such that thewrapper tubes are fed straight into the drum, not down, or at an angle.Brushes may be added to press lightly against the wrapper to providefriction to help prevent rotation. Air blow nozzles may help control thewrapper material's insertion into the slotted drum.

[0042] In one embodiment, a rotating cam that is downstream of rotatingshear knife is used. The rotating cam is coordinated in speed (rpm) withthe knife and the wrapper feeds. This rotating cam maintains the wrappermaterial in a pre-determined rotational position. The radial relief ofthe rotating cam comes into contact with a tube of wrapper materialprior to the cutting with the rotating shear knife and begins pushingthe tube of wrapper material on angle into a port on a slotted drum. Asthe tube of wrapper material begins to engage the slotted drum ports, avacuum port in the rotating cam opens and the vacuum positions andmaintains the tube of wrapper material in its pre-determined rotationalposition in the slotted drum port. The wrapper material may bemaintained in a pre-determined rotational position by others means.

[0043] The slotted drum has multiple ports in which the wrapper tubesare fed and has an indexing motion that moves the drum into multiplephases of the process. The wrapper tubes are fed on while the drum isstationary. Once in the ports of the slotted drum the discrete lengthsof wrapper material are held in place by vacuum. The drum indexes and asit does so, one of the transverse edges of the wrapper material is thensealed by a pair knurled nip rollers to form a transverse seal. Thetransverse seal has a width defined by a first end and a second end. Thetransverse seal is sealed such that the tear member on the wrappermaterial extends into the transverse seal adjacent to the first end. Atampon is provided with an axial length, a radial circumference, and aninsertion end opposed to a withdrawal end.

[0044] As the slotted drum continues to index, the open-ended wrapper isbrought in front of nozzle, which houses a tampon. The tampon isinserted into the wrapper material through the unsealed transverse edge.The slotted drum continues to index and the other end of wrappermaterial is sealed at the opposing transverse edge of the wrappermaterial by a pair knurled nip rollers to form a transverse seal havinga width defined by a first end and a second end. When the wrapper issealed the tear member is located about 3 mm, or typically 2 mm awayfrom the first ends of the transverse seals.

What is claimed is:
 1. A process for making a wrapped tampon comprisingthe steps of: providing a continuously moving wrapper material having alongitudinal axis, a pair of opposing longitudinal edges and a width;attaching a tear member to said wrapper material parallel to saidlongitudinal axis; positioning said wrapper material in a pre-determinedrotational position; folding said wrapper material along saidlongitudinal axis to overlap said pair of opposing longitudinal edges;sealing said pair of opposing longitudinal edges together to form alongitudinal seal; cutting said wrappper material to form a length and apair of opposing transverse edges; maintaining said wrapper material insaid pre-determined rotational position; sealing one of said transverseedges of said wrapper material to form a transverse seal having a widthdefined by a first end and a second end, said tear member extending intosaid transverse seal adjacent to said first end; providing a tamponhaving an axial length, a radial circumference, and an insertion endopposed to a withdrawal end; inserting said tampon into said wrappermaterial; and sealing said opposing transverse edge of said wrappermaterial to form a transverse seal having a width defined by a first endand a second end, said tear member extending into said transverse sealadjacent to said first end.
 2. The process according to claim 1, whereinthe wrapper material is maintained in a pre-determined rotationalposition by a rotating cam of a wheel.
 3. The process according to claim1, wherein the wrapper material is maintained in a pre-determinedrotational position by aligning said wrapper material with a port on aslotted drum.
 4. The process according to claim 1, wherein the wrappermaterial is maintained in a pre-determined rotational position by aapplying a means selected from the group consisting of vacuum, brushes,air nozzles and combinations thereof.
 5. The process according to claim1 wherein said wrapper material provided comprises a graphic registeredalong said tear member.
 6. The process according to claim 1 wherein oneof said transverse seals is a tear-initiating end, wherein said tamponmay be inserted such that the withdrawal end of the tampon is orientedwithin said wrapper material adjacent to the tear-initiating end.
 7. Theprocess according to claim 1 wherein said tear member is a bead of glue.8. The process according to claim 1 wherein said tear member is athread.
 9. The process according to claim 1 wherein said tear member islocated within about 3 mm of said first ends of said transverse seals.10. The according to claim 1 wherein said tear member is located withinabout 2 mm of said first ends of said transverse seals.
 11. A processfor making a wrapped tampon comprising the steps of: providing acontinuously moving wrapper material having a longitudinal axis, a pairof opposing longitudinal edges, a width and an attached tear member,said tear member being parallel to said longitudinal axis; positioningsaid wrapper material in a pre-determined rotational position; foldingsaid wrapper material along said longitudinal axis to overlap said pairof opposing longitudinal edges; sealing the pair of opposing overlappinglongitudinal edges together to form a longitudinal seal; cutting saidwrappper material to form a length and a pair of opposing transverseedges; maintaining said wrapper material in said pre-determinedrotational position; sealing one of said transverse edges of saidwrapper material to form a transverse seal having a width defined by afirst end and a second end; said tear member extending into saidtransverse seal adjacent to said first end; providing a tampon having anaxial length, a radial circumference, and an insertion end opposed to awithdrawal end; inserting said tampon into said wrapper material;sealing said opposing transverse edge of said wrapper material to form atransverse seal having a width defined by a first end and a second end,said tear member extending into said transverse seal adjacent to saidfirst end.
 12. The process according to claim 11, wherein the wrappermaterial is maintained in a pre-determined rotational position by arotating cam of a wheel.
 13. The process according to claim 11, whereinthe wrapper material is maintained in a pre-determined rotationalposition by aligning said wrapper material with a port on a slotteddrum.
 14. The process according to claim 11, wherein the wrappermaterial is maintained in a pre-determined rotational position by aapplying a means selected from the group consisting of vacuum, brushes,air nozzles and combination thereof.
 15. The process according to claim11 wherein said wrapper material provided comprises a graphic registeredalong said tear member.
 16. The process according to claim 11 whereinon2 of said transverse seals is a tear-initiating end, wherein saidtampon may be inserted such that the withdrawal end of the tampon isoriented within said wrapper material adjacent to the tear-initiatingend.
 17. The process according to claim 11 wherein said tear member is abead of glue.
 18. The process according to claim 11 wherein said tearmember is a thread.
 19. The process according to claim 11 wherein saidtear member is located within about 13 mm of said first ends of saidtransverse seals.
 20. The process according to claim 11 wherein saidtear member is located within about 2 mm of said first ends of saidtransverse seals.